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Brush SealsGeneral Product Introduction
Issue No. 1 – 21 Aug 2013
WBC - Confidential
What is a brush seal?
• A brush seal is an “engineered” product.
• Brush seals utilize a “bristle pack” comprised of thousands of small diameter wires which follow shaft movement.
• Product Definition:– Defined as a compliant contacting seal
– Provides controlled leakage
– Classified as a circumferential seal
• Configuration:– Front and back plates
– Bristle Pack
– Circular and Linear geometries
– Solid, split and multi-segment
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Shaft
Front Plate
Bristle Pack
Back Plate
Flow
WBC - Confidential
Theory of Operation
3
Labyrinth_Animation.wmv Brush_Animation.wmv
Rolled Over TeethCompliant
Bristle Pack
WBC - Confidential
Compliant bristles reduce the leakage gap resulting from traditional labyrinth seals
Rubs can be caused thermally or from rotor dynamics (critical speeds)
Ideal Applications for:
High excursions (rotor/stator interference)
Air, gas, and steam sealing
Pressure reduction
Equipment Types:
Gas Turbines
Steam Turbines
Centrifugal Compressors
Turboexpanders
Brush Seal Fundamentals
4
Brush seals can reduce leakage up to 80% or more in certain
applications
WBC - Confidential 5
80’s – Aerospace Initiates Development
Early 90’s – R&D Contracts (US Gov’t, NASA, DOE)
Mid 90’s – Aerospace Acceptance with Jet Engines
Late 90’s – Industrial Gas Turbines and Large Steam Turbines Begin to Adopt Technology
Early 2000’s – Other Turbomachinery applications begin to develop (eg. compressors, expanders, etc.)
2008 – Eaton Aerospace extends exclusive license to Waukesha Bearings
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Brush Seals - History
US Patents 6,231,047 B1 and 7,461,847
WBC - Confidential
Brush Seal Characteristics
Operating Parameters
Pressures: Up to 300 psid (20 bars) per brush seal
Temperatures: Up to 1,200 F (650 C)
Surface Speeds: up to 1,100 ft/sec (335 m/s)
Environments: Gas Path (Air, Steam); Bearing (Air Management)
Materials of Construction
Housing: Stainless, Inconel, Bronze
Bristles: Haynes 25
Sizes and Configuration
Diameters up to 120” (3000 mm)
Low Profile (3/16” axial x 5/8” radial)
Solid, Split, and Multi-segmented Rings
Bristle Strip
Radial Height
Rotor
Fence Height
Flow
Back PlateFront Plate
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US Patent 6,231,047 B1
WBC - Confidential
Benefits of Waukesha’s Brush Seal
US Patent 6,231,047 B1
Lower Cost of Ownership
– Replaceable Bristle Pack
– Up to 30% Reduction in Replacement Costs
– 3 to 5 week Turn-time to Repair
Readily Available
– Flexible Strip and Rings cover ¾” diameters and up
– 6 to 8 week leadtimes on Modular Designs*
– 3 to 5 weeks on Augmented Labys **customer supplied labyrinth
Easy to Retrofit Existing Hardware
– < ¼” Axial Requirement (hook)
Proven Technology
– Aerospace qualified
Before After
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Competition – “Not Refurbishable”
Bristles welded between plates
Waukesha’s – “Refurbishable”
WBC - Confidential
Custom Engineered Solutions - Examples
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Modular Assemblies
Augmented Labyrinths
W501 GT
Steam Turbine
Steam Turbine (J-Strips)GE Frame GTGE Frame GT
Steam TurbineSteam Turbine Steam Turbine (Baffle)
WBC - Confidential
Typical Applications and Benefits
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Modular Assemblies
Augmented Labyrinths
Floating Brush Seals
Industrial Gas Turbines
Steam Turbines&
Compressors
Process Steam Turbines
Efficiency Gains (1-3%)Refurbishable (30% less)Quick Turns• New: 6 – 8 wks (GT)• Refurb: 3 -5 wks (GT)
Efficiency Gains (>2%)Replaceable (30% less)3 -5 wk Turn-around*
*customer supplied laby
Drop-in Replacement+3X life improvement• 3 yr vs 6-12 months
Applications Benefits/Differentiators
US Patents 6,231,047 B1 and 7,461,847
WBC - Confidential 1010
Compressor Discharge (HPP) Bearing Sump Sealing Interstage Sealing
Common MachinesGas Turbine Applications – Brush Seals
Size range: 25MW and Up
WBC - Confidential 11
Industrial and Utility Steam Turbines
WBC - Confidential
Brush Seal vs Labyrinth – 5 Year Maintenance Cycle (Steam Turbine)
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2% Efficiency Improvement
WBC - Confidential
Monetarizing the Benefits of Increased Electricity Sales
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2% Efficiency Improvement
Assumptions
‒ 500MW Steam Turbine
‒ 24/7/365 Duty Cycle
‒ Brush Seals applied to End Packing Labys
‒ 2% Efficiency Gain
‒ 5 year maintenance cycle
‒ Electricity Rate: 0.06 USD/kw-hr
‒ $200K purchased in brush seals
REWARD TO END USER
• 10 additional MW per year to sell to grid• Additional Revenues:
• 1 day: $14.4K/day• 1 year: $5.3 M/yr • 5 years: $26.5M
• Brush Seal Payback : < 2 weeks
• Technology Risk: Low
Brush Seals can provide:
• An Immediate Payback
• A Low Risk Upgrade
WBC - Confidential
Centrifugal Compressors – Closed Impeller
Impeller Eye
Impeller Hub
(Shaft)
Balance Piston
Closed Type Impeller
Why consider WB’s brush seal?
Laby wear (Al)
Efficiency Gains
Tight Real Estate
Compliancy in AMBs
Equipment Types:
Pipeline compressors
Barrel compressors
Waste treatment blowers
WBC - Confidential
Centrifugal Compressors – Open Impeller
Why consider WB’s brush seal?
Laby wear (Al)
Efficiency Gains
Tight Real Estate
Compliancy in AMBs
Equipment Types:
Heat Recovery Systems
Turbo Expanders
Air compression (geared)
Open Type Impeller
brush seal locations
WBC - Confidential
Floating Brush Seals for Elliott YR TurbinesAvailable for AYR, BYR, CYR and DYR models
Up to 3x lifevs
carbon rings
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• Plug-n-Play Replacement split design provides direct replacement of carbon rings
• 3X Life Improvement demonstrated 3 yr life over 6 to 12 months with carbon rings
• Predictable leakage (low and stable) over an extended operating life compared to carbon rings
• Self – centering and lightweight utilizing carbon element which also provides effective cavity sealing
• Compliant brush seal allows “wear-in” to optimum fit and eliminates incorrect bore sizing problems
• Protects downstream carbon rings from contamination and high pressure
• Prevents secondary damage to bearings and leakage to atmosphere
• Highly resistant to corrosion and high temperatures
• Reduces maintenance, downtime and steam losses
steam
WBC - Confidential
Detailed Definition – Floating Brush Seals
Split assembly eliminates rotor removal for a plug-n-play replacement.
Retainer for Carbon
Carbon(centering & cavity sealing)
Retainer for Brush Seal
Brush Seal (radial sealing)
Spring(holds assembly
together)
Anti-Rotation Clip (not shown)
Split halves
Complete assembly
US Patent 7,461,847
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Steam Flow
WBC - Confidential
Sentinel™ FBS - Characteristics
Operating Parameters
Pressures: Up to 150 psid (10 bar)
Temperatures: Up to 850 F (450 C)
Surface Speeds: up to 160 ft/sec (50 m/s)
Environment: Steam
Configuration and Materials
Split ring assembly (two-halves)
Aerospace qualified bristle ring
Specialty grade carbon ring
Stainless steel components
Available Designs
Elliott AYR/BYR: 2.25” (57.15mm) shaft
Elliott CYR/DYR: 3” (76.20mm) shaft
Other designs available upon request
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Operating Parameters are limited to the performance of the carbon element.
WBC - Confidential
Our Capabilities – Brush Seals
Engineering and Test
‒ Proprietary design code to model seal leakage and rotor-dynamics effects
‒ Custom seal designs
‒ Reverse engineered seals
• Frame Gas Turbines
• Steam Turbines
‒ Static test capability
‒ Dynamic test under-development
Manufacturing and Assembly
‒ (2) locations (25,000 sq ft ea)
• Houston, Texas (Bearings Plus)
• Rhode Island (Waukesha Bearings)
‒ 2014 Expansion (180,000sq. ft facility)
WBC - Confidential
Application Check List (for Custom Seal Designs)
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General Information
Turbine Make/Model
Brush seal location
No. Seals Required
Date Hardware Required
Operating Conditions
Rotor speed
Sealed fluid
Upstream pressure
Downstream pressure
Temperature upstream
Temperature downstream
Application Details
Provide drawing of area where seal would be located
Labyrinth material, if used
Diameter and tolerance of rotor
Rotor material
Provide details on rotor coating or sleeve, if applicable
Centrifugal growth
Thermal growth
Max. radial excursions
Bearing clearance
Axial movement of rotor
Max. housing/rotor closure
Dynamic radial movement
Housing concentricity to rotor
Describe any unique operating conditions that should be considered in designing the seal (e.g. fast start, reverse pressurization, reverse rotation, pressure/flow slugs, etc.)
Data inquiry form available on WB and BPI websites
Bristle Strip
Radial Height
Rotor
Fence Height
Flow
Back PlateFront Plate
WBC - Confidential
General Information
Turbine Make/Model
Brush seal location
OEM Part Number
No. Seals Required
Date Hardware Required
Application Details
Preferred - Provide sample of new or used brush seal, (if used how many hours were logged?)
Alternative – Provide drawing of seal inclusive of all features to ensure proper fit-up
Provide pictures of hardware
Provide any applicable performance data on existing seal (before/after) and/or description of any unique operating conditions
Application Check List (for Reversed Engineered Seals)
WBC - Confidential
Why Choose Brush Seals and Waukesha?
• Replaceable Bristle Pack
• Low Risk Upgrade
• Favorable Payback
• Demonstrated Experience
• Technical Know-how
• Solutions Oriented
• Global Reach and Support
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